Enhanced systems that facilitate vacuum bag curing of composite parts

ABSTRACT

Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a selected location for placing the composite part on the tool, to direct the dispensers to apply a mold release agent onto the tool based on the selected location, to apply a sealant onto the tool proximate to the selected location, to lay up a ply of constituent material for the composite part atop the mold release agent at the selected location, to apply a pressure pad material atop the constituent material, to apply a breather material atop the pressure pad, and to apply vacuum bag material atop the ply proximate to the selected location to cover the ply as well as the sealant.

FIELD

The disclosure relates to the field of composite parts, and inparticular, to curable composite parts.

BACKGROUND

Many composite parts (e.g., carbon fiber products, such as aircraftwings) are created via vacuum bag curing processes. Using thesetechniques, a laminate of plies of constituent material is laid-up ontoa forming tool that will mold the constituent material into a desiredshape. In order to ensure that the laminate consolidates into thedesired shape, a vacuum bag is constructed around the laminate andsealed to the forming tool. As air is drawn from the vacuum bag, the bagapplies pressure to contour and consolidate the laminate against theforming tool. The vacuum bag also removes volatile compounds presentwithin the laminate. Heat may also be applied to the composite part aspart of a process to cure the laminate into a solid. The process oflaying-up and curing laminates may be repeated over time to fabricateco-bonded structures.

As a part of preparing the tool for laying-up a composite part, volatilechemicals may be used to form the release agents that enable thecomposite part to be removed from the tool after it is cured. This inturn creates a need for expensive ventilation and safety equipment.Furthermore, undesirable application of vacuum bagging materials tocomposite parts may result in the formation of air bubbles and otherinconsistencies within a composite part being fabricated.Inconsistencies in a composite part cause it to exhibit tolerancingissues. For mission-critical composite parts (e.g., the wings of anaircraft), such inconsistencies may be unacceptable, meaning that partswith out of tolerance inconsistencies may need to be scrapped orreworked. Hence, the industry continues to seek out enhanced techniquesfor fabricating composite parts in a manner that decreases cost and/orincreases quality.

SUMMARY

Embodiments described herein provide for systems that utilizecomputer-aided techniques to dispense consumable materials for vacuumbagging a composite part. Further embodiments provide for enhancedforming tools capable of measuring and/or altering the temperature of acomposite part during curing, as well as enhanced methods for utilizingand/or manufacturing such forming tools.

One embodiment is a system for automated dispensing and assembly ofvacuum bagging materials for a composite part. The system includesdispensers configured to dispense materials onto a forming tool for acomposite part, and a controller. The controller is able to identify alocation for placing the composite part on the tool, to direct thedispensers to lay up a laminate of constituent material for thecomposite part at the location, and to spray vacuum bag material atopthe laminate proximate to the location to cover the laminate.

A further embodiment is a method for automated dispensing and assemblyof vacuum bagging materials for a composite part. The method includesidentifying a location for placing a composite part on a forming tool.The method also includes directing a dispenser to lay up a laminate ofconstituent material for the composite part at the location, anddirecting a dispenser to dispense vacuum bag material atop the laminateproximate to the location to cover the laminate.

A further embodiment comprises a non-transitory computer readable mediumembodying programmed instructions which, when executed by a processor,are operable for performing a method for automated dispensing andassembly of vacuum bagging materials for a composite part. The methodincludes identifying a location for placing a composite part on aforming tool, and directing a dispenser to lay up a laminate ofconstituent material for the composite part at the location. The methodalso includes directing a dispenser to spray vacuum bag material atopthe laminate proximate to the location to cover the laminate.

A further embodiment is a system for automated dispensing and assemblyof vacuum bagging materials for a composite part. The system includes acontroller, a first dispenser configured to dispense constituentmaterial for a composite part atop a forming tool, and a seconddispenser configured to dispense a consumable material that facilitatesvacuum bagging processes at the composite part, in response toinstructions from the controller that are based on a geometry of thecomposite part.

A further embodiment is an enhanced forming apparatus for a compositepart. The apparatus includes a forming tool configured to hold acomposite part in a defined shape while the composite part is curing ina vacuum bag sealed to the tool, a thermocouple integrated within thetool configured to sense temperature at a surface of the tool, andtraces integrated within the tool that carry temperature signalsgenerated by the thermocouple while the composite part is curing.

A further embodiment is a method for operating an enhanced formingapparatus. The method includes initiating curing of a composite part ina vacuum bag sealed to a forming tool holding the composite part in adefined shape, detecting a temperature of the composite part duringcuring via a thermocouple integrated into the tool, and adjusting heatapplied to the composite part in response to the detected temperature.

A further embodiment is a further enhanced forming apparatus for acomposite part. The apparatus includes a forming tool configured to holda composite part in a defined shape while the composite part is curingin a vacuum bag sealed to the tool, a heating element integrated withinthe tool configured to generate heat that conducts to a surface of thetool, and traces integrated within the tool that provide power to theheating element while the heating element is generating heat.

A still further embodiment is a method for operating an enhanced formingapparatus. The method includes initiating curing of a composite part ina vacuum bag sealed to a forming tool holding the composite part in adefined shape, detecting a temperature of the composite part duringcuring, and adjusting an amount of heat applied to the composite part inresponse to the detected temperature by energizing a heating elementintegral with the forming tool.

A still further embodiment is a system for printing an enhanced formingapparatus. The system includes a controller able to identify a threedimensional (3D) shape for a forming tool that holds a composite partwhile the composite part is curing, and a 3D printer able to print basematerial in response to commands from the controller to create a portionof the tool based on the 3D shape. The controller is configured toidentify a location of an electrical component within the forming tool,to print a groove in the forming tool at the location, to direct adispenser to place the electrical component into the groove before thetool has finished printing, and to print base material on top of theelectrical component to cover the groove and seal the electricalcomponent into the tool.

A still further embodiment is a method for operating a system forprinting an enhanced forming apparatus. The method includes identifyinga three dimensional (3D) shape of a forming tool that is configured tohold a composite part in a defined shape while the composite part iscuring in a vacuum bag. The method also includes printing base materialbased on input in order to create a portion of the forming tool based onthe 3D shape, identifying a location of a thermocouple within the tool,and printing a groove into the forming tool at the location. The methodalso includes directing a dispenser to place the thermocouple into thegroove before the tool has finished printing, and printing base materialon top of the thermocouple to cover the groove and seal the thermocoupleinto the tool.

A still further embodiment is a method for recycling a formingapparatus. The method includes imaging a forming tool, determining a new3D shape for the forming tool, generating instructions for printingmetal onto the forming tool to alter the forming tool into the 3D shape,and directing the 3D printer to print metal onto the forming tool basedon the instructions.

Yet another embodiment is a method for operating a system for printingan enhanced forming apparatus. The method includes identifying a threedimensional (3D) shape of a forming tool that is configured to hold acomposite part in a defined shape while the composite part is curing ina vacuum bag. The method also includes printing base material based oninput in order to create a portion of the forming tool based on the 3Dshape, identifying a location of a heating element within the tool, andprinting a groove into the forming tool at the location. The method alsoincludes directing a dispenser to place the heating element into thegroove before the tool has finished printing, and printing base materialon top of the heating element to cover the groove and seal the heatingelement into the tool.

Yet another embodiment is an apparatus with enhanced cart electronicsfor a composite part. The apparatus includes a cart body, and multiplelegs attached to the cart body, each leg comprising a foot adapted forinsertion into a corresponding foot pad of an autoclave. The apparatusalso includes an electrical connector that is proximate to one of thefeet and is configured to electrically couple with an outlet of theautoclave when the feet are inserted into the autoclave, providing powerto the cart.

Other exemplary embodiments (e.g., methods and computer-readable mediarelating to the foregoing embodiments) may be described below. Thefeatures, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

DESCRIPTION OF THE DRAWINGS

Some embodiments of the present disclosure are now described, by way ofexample only, and with reference to the accompanying drawings. The samereference number represents the same element or the same type of elementon all drawings.

FIG. 1 is a block diagram of an automated bagging system in an exemplaryembodiment.

FIG. 2 is a flowchart illustrating a method for operating an automatedbagging system in an exemplary embodiment.

FIGS. 3-10 are diagrams illustrating application of consumable curingmaterials for a composite part in an exemplary embodiment.

FIG. 11 is a flowchart illustrating a method for selectively adding morevacuum bagging material in an exemplary embodiment.

FIG. 12 is a diagram illustrating a forming tool enhanced withintegrated thermocouples in an exemplary embodiment.

FIG. 13 is a flowchart illustrating a method for utilizing a formingtool enhanced with integrated thermocouples in an exemplary embodiment.

FIG. 14 is a block diagram of a system configured to manufactureenhanced forming tools in an exemplary embodiment.

FIG. 15 is a flowchart illustrating a method of operating the system ofFIG. 14 to print a forming tool in an exemplary embodiment.

FIGS. 16-20 are diagrams illustrating printing of an enhanced formingtool in an exemplary embodiment.

FIG. 21 is a diagram illustrating a forming tool enhanced withintegrated heating elements and electronics in an exemplary embodiment.

FIG. 22 is a diagram illustrating application of heat by a forming toolof FIG. 21 in an exemplary embodiment.

FIG. 23 is a block diagram illustrating an enhanced forming tool in anexemplary embodiment.

FIG. 24 is a flowchart illustrating a method for utilizing additivemanufacturing to modify an existing forming tool in an exemplaryembodiment.

FIG. 25 is a diagram illustrating a forming tool before it is modifiedaccording to the method of FIG. 24.

FIG. 26 is a diagram illustrating a forming tool after it is modifiedaccording to the method of FIG. 24.

FIG. 27 is a diagram illustrating an enhanced cart with an electricalconnector adapted to mate with a power system of an autoclave in anexemplary embodiment.

FIG. 28 is a diagram illustrating an enhanced cart with an electricalconnector that is mated with a power system of an autoclave in anexemplary embodiment.

FIG. 29 is a block diagram illustrating an enhanced cart in an exemplaryembodiment.

FIG. 30 is a flow diagram of aircraft production and service methodologyin an exemplary embodiment.

FIG. 31 is a block diagram of an aircraft in an exemplary embodiment.

DESCRIPTION

The figures and the following description illustrate specific exemplaryembodiments of the disclosure. It will thus be appreciated that thoseskilled in the art will be able to devise various arrangements that,although not explicitly described or shown herein, embody the principlesof the disclosure and are included within the scope of the disclosure.Furthermore, any examples described herein are intended to aid inunderstanding the principles of the disclosure, and are to be construedas being without limitation to such specifically recited examples andconditions. As a result, the disclosure is not limited to the specificembodiments or examples described below, but by the claims and theirequivalents.

The following systems and techniques may be implemented in a fabricationenvironment where multiple individual composite parts are made over timein accordance with vacuum bagging techniques. In this fabricationenvironment, forming tools themselves may be manufactured and/ormodified in order to ensure that they are capable of molding laminatesinto expected shapes. After the forming tools have been manufactured,laminates are laid-up onto the forming tools, bagged, and cured (e.g.,by placing the forming tools into mobile carts that are moved into anautoclave). FIGS. 1-11 herein discuss enhanced systems and techniquespertaining to automated vacuum bagging processes, while FIGS. 12-26describe enhanced forming tools that may be used to facilitate thefabrication of composite parts. FIGS. 27-29 describe enhanced carts thatmay be utilized in conjunction with the enhanced forming tools of FIGS.12-26.

Automated Placement of Consumables for Vacuum Bagging

FIG. 1 is a block diagram of an automated bagging system 150 in anexemplary embodiment. System 150 comprises any system or device that iscapable of automatically applying one or more consumable materialsutilized during the bagging and/or curing process for a composite part130. For example, system 150 may dispense consumable materials atopand/or beneath composite part 130 to prepare composite part 130 forvacuum bag curing. Composite part 130 (e.g., a laminate of constituentmaterial, comprising one or more plies) rests atop forming tool 120,which itself is placed atop mobile cart 110. In this manner, after part130 has been properly vacuum bagged, cart 110 may be rolled into anautoclave (not shown in FIG. 1, but illustrated as 2700 of FIG. 27) toinitiate the curing of part 130. As shown in FIG. 1, exemplary materialsthat may be dispensed by system 150 include mold release agent 141,sealant 142, pressure pad/caul 143, breather 144, and vacuum bag 145.

In this embodiment, system 150 comprises dispensers 154, controller 152,and imaging system 156. Imaging system 156 comprises any camera and/orsensors system that is capable of acquiring picture and/or video data ina two dimensional (2D) and/or three dimensional (3D) format forutilization by controller 152. Based on this information, controller 152directs the operations of dispensers 154 as they dispense consumablematerials (e.g., materials that may be used once or a number of timesbefore eventually being disposed of) for vacuum bagging of compositepart 130. For example, controller 152 may utilize input from imagingsystem 156 to detect a border 131 of part 130, and then may directdispensers 154 to apply consumable materials based upon the border 131of part 130. Controller 152 may be implemented, for example, as customcircuitry, as a processor executing programmed instructions, or somecombination thereof.

Dispensers 154 dispense consumable materials onto composite part 130based on directions provided by controller 152. Dispensers 154 mayinclude spray heads 154-1 and/or nozzles 154-2 configured to sprayconsumable materials in liquid form. These liquid materials may thensolidify over a period of several seconds or minutes into a solid, atwhich point in time another consumable material may be added, or cart110 may be inserted into an autoclave (FIG. 27, 2700) for curing ofcomposite part 130. In one embodiment, at least one of dispensers 154comprises a spray nozzle 154-2 mounted on a five-axis gimbal (not shown)capable of moving in three dimensions (e.g., X, Y, Z) based on inputfrom controller 152. Each of dispensers 154 may comprise a differenttype of dispenser, and/or may dispense a different consumable materialfor use in vacuum bag curing.

Dispensers 154 may also include one or more Automated Fiber Placement(AFP) machines 154-3, or similar devices, utilized to lay-up a layer ofconstituent material for composite part 130, and/or to lay-up otherconsumable materials that may be dispensed as plies. This may include,for example, vacuum bagging material, sealant tape, peel plies,breathers, pressure pads, etc. Dispensers 154 may further includeextruders 154-4 that are configured to extrude consumable materials inliquid/gel form for use in vacuum bagging (e.g., as described withregard to FIG. 2). For example, an extruder may be used to extrude gelsealant in lieu of sealant tape for a composite part. In a furtherembodiment, at least one of dispensers 154 comprises a robotic arm 154-5configured to retrieve and position sheets of consumable material ontopart 130.

System 150 may be sealed from the external environment, and may utilizedifferent environmental parameters than its surroundings. For example,an interior 151 of system 150 may be operated at a different temperatureand/or pressure than the ambient environment, and the air inside ofsystem 150 (if any) may exhibit a different combination of gases thanthe surroundings. For example, gas within interior 151 may exhibit moreoxygen (e.g., parts per million (PPM)) than the exterior in order tocause dispensed materials to react and solidify more quickly. Or, gaswithin interior 151 may exhibit less oxygen (PPM) than the surroundingsin order to cause dispensed materials to solidify less quickly.

Illustrative details of the operation of system 150 will be discussedwith regard to FIG. 2. Assume, for this embodiment, that cart 110 andtool 120 have been placed into system 150, but that no composite parthas yet been placed upon tool 120. Further, assume that controller 152has loaded data into an internal memory indicating a geometry to belaid-up for part 130.

FIG. 2 is a flowchart illustrating a method 200 for operating anautomated bagging system in an exemplary embodiment. The steps of method200 are described with reference to system 150 of FIG. 1, but thoseskilled in the art will appreciate that method 200 may be performed inother systems. The steps of the flowcharts described herein are not allinclusive and may include other steps not shown. The steps describedherein may also be performed in an alternative order. The stepsdescribed in FIG. 2 are illustrated by FIGS. 3-10, which are diagramsillustrating application of consumable curing materials for a compositepart in an exemplary embodiment.

In step 202, controller 152 identifies a location for placing part 130onto tool 120. For example, controller 152 may operate imaging system156 to identify the orientation and position of tool 120, and may thencorrelate this data with information that indicates a position that part130 will occupy when it is placed or laid-up upon tool 120. FIG. 3illustrates location 302 for part 130 on tool 120.

After location 302 is known, controller 152 takes steps to ensure thatpart 130 will properly release from tool 120 after curing is completed.To this end, controller 152 directs one of dispensers 154 to apply amold release agent 141 onto tool 120 at location 302 (step 204). Forexample, controller 152 may direct a dispenser to dispense the moldrelease agent 141 directly onto location 302, and also within a certainthreshold of distance of location 302 (e.g., location 302, plus a onecentimeter border zone). Location 304 of FIG. 4 indicates where moldrelease agent 141 is dispensed atop tool 120 in an exemplary embodiment.

The mold release agent 141 may be applied as an aerosol spray, as anextruded liquid, as a ply of material or via any suitable technique. Inone embodiment, the mold release agent 141 is applied by a dispenser asan aerosol spray to evenly coat tool 120 in a thin layer. The moldrelease agent 141 may comprise any suitable agent that facilitates theseparation of part 130 from tool 120 after completion of curing (e.g., aFrekote 700-NC product).

In directing one or more dispensers 154, controller 152 may provideinstructions for repositioning the dispenser to a new location, changingthe angle and/or tilt of the dispenser, activating the dispenser, and/ordeactivating the dispenser in order to ensure that consumable materialsare dispensed at appropriate locations. This may include providinginstructions to adjust a 2D position of the dispenser within system 150,and may further include instructions for altering a height of thedispenser while operating the dispenser. These techniques may beutilized, for example, to ensure that a spray head of the dispenserremains a constant height above location 304, even when the contours offorming tool 120 rise or fall. Further instructions from controller 152may indicate a pressure at which to spray mold release agent 141. Byvarying these parameters, controller 152 may apply a coat of suitablethickness at each desired location without spraying outside of theintended area. Furthermore, since the locations at which to applyconsumable materials may be determined by controller 152 based on thegeometry of the composite part, these consumable materials may be usedmore efficiently than in systems that apply the materials by hand.

In step 206, controller 152 directs one of dispensers 154 to applysealant 142 onto tool 120 proximate to the location 304 (e.g., along aborder or periphery of location 304). For example, FIG. 5 illustratesthat sealant 142 is dispensed at location 306, which surrounds aperiphery/border of location 304 but does not intersect location 304.Sealant 142 enables a vacuum bag to be sealed onto tool 120, therebyproviding an evacuated environment for a composite part to be cured.Controller 152 may apply sealant 142 in accordance with a predefinedplan, or controller 152 may automatically calculate the where to applysealant 142. For example, controller 152 may apply sealant 142 along aproximate to border 304-1 that surrounds location 304 or that surroundswhere the composite part will be placed, at some setoff distance (e.g.,D) away from any mold release agent 141, etc.

In some embodiments, sealant 142 may be compromised if it is sprayeddirectly onto mold release agent 141. Thus, controller 152 may direct adispenser to apply a mask (not shown) to tool 120 before applying moldrelease agent 141, and then may remove the mask (not shown) beforeapplying the sealant 142. This ensures that no mold release agent 141reaches areas on tool 120 where sealant 142 will be placed. Controller152 may alternatively chemically clean mold release agent 141 fromlocation 306 where sealant 142 will be applied, or may carefully directthe application of mold release agent 141 to ensure that it is notdispensed onto location 306 (e.g., at a concentration that wouldinterfere with sealant 142).

If the first layer of composite part 130 has not yet been laid, thenprocessing may proceed to step 208 below. Alternatively, if multiplelayers of composite part 130 have already been laid-up and cured, thencontroller 152 may direct one of dispensers 154 (e.g., a robot arm) toplace composite part 130 onto tool 120 atop mold release agent 141. Onceplaced, part 130 will be positioned to enable lay-up of anotherlayer/ply of constituent material (e.g., carbon fiber).

In step 208, controller 152 directs one of dispensers 154 (e.g., an AFPmachine) to lay up one or more plies of constituent material into alaminate 308 for composite part 130 at location 304 (i.e., atop moldrelease agent 141). In embodiments where composite part 130 has alreadybeen placed onto tool 120, laminate 308 is laid directly onto compositepart 130, which is itself directly atop mold release agent 141. Infurther embodiments, laminate 308 is laid directly onto portions of tool120 that include mold release agent 141. This step is shown in FIG. 6.Laminate 308 will cure into composite part 130 after it has been vacuumbagged and heated in an autoclave. However, in its current form,laminate 308 is not yet cured. In some embodiments, controller 152further directs a technician or one of dispensers 154 apply a peel plyonto laminate 308. A peel ply is an interlayer that is used to ensurethat vacuum bagging materials will not bond to laminate 308 whilelaminate 308 is curing.

Depending on the part being made, a pressure pad may be desired tofacilitate curing. Thus, in one embodiment, in step 210 controller 152directs one of dispensers 154 to apply a pressure pad material 310 (alsoknown as a “caul plate”) atop laminate 308 (e.g., directly atop laminate308, or atop a peel ply that itself directly contacts laminate 308).This is shown in FIG. 7 where pressure pad material 310 is dispensedatop laminate 308. Dispensing pressure pad material 310 may comprisedirecting a robot arm to acquire a pre-made pressure pad (e.g., from asupply of pressure pads) and place the pressure pad atop laminate 308.In a further embodiment, pressure pad material 310 is sprayed atoplaminate 308 (e.g., via a spray nozzle dispenser), or 3D printed asliquid polymer. Controller 152 waits for a period of time to ensure thatpressure pad material 310 cures/solidifies before proceeding to step212. Pressure pad material 310 may comprise a room-temperature curingthermosetting mat material (e.g., a 5-minute epoxy) that is one eighthof an inch thick. In a further embodiment, a peel ply is added tolaminate 308, to a breather material 312 (FIG. 8), to a vacuum bagmaterial 318 (FIG. 10), and to pressure pad material 310.

In step 212, controller 152 directs one of dispensers 154 to dispense abreather material 312 (e.g., a polyester mat) atop laminate 308 (and,for example, also over pressure pad material 310). This is shown in FIG.8 where breather material 312 is dispensed atop pressure pad material310. Breather material 312 comprises an open cell material capable ofallowing air to travel freely through it. Breather material 312 may bedispensed from a supply of breathers by a robot arm, or may be sprayedand allowed to solidify over time. That is, controller 152 may wait forbreather material 312 to harden before proceeding with a next step.

In further embodiments, a parting film and/or peel ply may be appliedbetween any of the various materials discussed herein. The parting filmmay be sprayed as an ethylene tetrafluoroethylene (ETFE) orpolytetrafluoroethylene (PTFE) spray that polymerizes into a hardenedsolid may be applied between the various layers by one of dispensers154. In this manner, the parting film will prevent neighboring layersfrom interfering with each other.

With these materials in place, controller 152 may direct a robot arm ortechnician to place a port 314 atop breather material 312 as shown inFIG. 9. Hollow shaft 316 is located above port 314, and may provide anair pathway 317 for air to travel through port 314. With port 314 andshaft 316 in place, in step 214, controller 152 directs one ofdispensers 154 to spray vacuum bagging material 318, proximate to thelocation of laminate 308 such that vacuum bag material 318 coverslaminate 308 as well as sealant 142. This process may involve controller152 identifying the location 306 of sealant 142 as it surrounds thecomposite part, and then spraying vacuum bagging material 318 on top ofthe composite part and sealant 142. In this embodiment, vacuum baggingmaterial 318 is sprayed atop laminate 308, but the vacuum baggingmaterial 318 is not directly on top of laminate 308. For example, vacuumbagging material 318 may be sprayed directly atop breather material 312.Controller 152 may further identify port 314, and direct dispensers 154to surround the port with vacuum bagging material 318, without cloggingair pathway 317 of hollow shaft 316.

Vacuum bagging material 318 may be applied in a liquid form and sprayed.In embodiments where vacuum bagging material 318 is sprayed, a dispenser154 for vacuum bagging material 318 may be positioned beside shaft 316,so that dispenser 154 is located beneath the top of shaft 316, but aboveport 314 while spraying. This ensures that sprayed vacuum baggingmaterial 318 will not clog shaft 316 or otherwise interfere with thepassage of air out of port 314 and through shaft 316.

In embodiments where vacuum bagging material 318 is applied as a liquid,it may penetrate and/or block a portion of breather material 312. Thus,it may be desirable to dispense more breather material 312 than wouldtypically be used in step 212, in order to account for issues of cellpenetration and blockage in breather material 312. In these embodimentswhere vacuum bagging material 318 is liquid, it may comprisepolyethylene latex, neoprene, etc. Infrared heat may also be applied tovacuum bagging material 318 after it is dispensed, in order to ensurevacuum bagging material 318 solidifies rapidly. Using a liquid form forvacuum bagging material 318 also provides a benefit in that it preventsissues with bag bridging and breaching. Since the vacuum bag material318 solidifies onto the composite part, it does not bridge substantialgaps when a vacuum is drawn.

In a further embodiment, vacuum bagging material 318 is applied as aliquid spray and is impregnated with a colored dye (e.g., a fluorescentdye, infrared dye, visible light dye, etc.). FIG. 11 is a flowchartillustrating a method 1100 for selectively adding more vacuum baggingmaterial 318 based on the presence of colored dye in an exemplaryembodiment. Upon completion of step 214, controller 152 operates imagingsystem 156 to image a surface of material 318 after it has solidifiedafter spraying (step 1102). Controller 152 analyzes data from imagingsystem 156 to determine a dye density along the surface of material 318in step 1104. Controller 152 then identifies locations along the surfacethat have dye density of less than a threshold value in step 1106 (e.g.,based on a color of the imaged locations) in an inspection process.Controller 152 then directs one of dispensers 154 to spray additionalvacuum bagging material 318 at these locations in step 1108. Thistechnique of selectively reinforcing vacuum bagging material 318 reducesthe chance of a vacuum bag rupture when composite part 130 is cured inan autoclave. This step may be performed before, after, or even duringthe application of a vacuum to the vacuum bagging material 318.

After the vacuum bagging process is complete, a vacuum may be drawn onmaterial 318 to test for leaks. If there are no leaks, composite part130 may be inserted into an autoclave, may have a vacuum drawn, and maybe heated in order to cure ply 308. After composite part 130 has beencured, it is removed from forming tool 120, and the consumable materialsused for vacuum bagging are discarded (e.g., peel plies, vacuum baggingmaterial 318, breather material 312, pressure pad 310, sealant 142,and/or mold release agent 141). Controller 152 may then repeat steps202-214 to lay-up a next layer for composite part 130. In this manner,composite parts may be automatically prepared for curing by system 150of FIG. 1.

In a further embodiment, sealant 142 comprises a temperature-sensitiveadhesive chemical that loses grip at lower temperatures. In thisembodiment, after composite part 130 has completed curing, it may beplaced into a refrigerated chamber and cooled to a temperature thatcauses sealant 142 to have reduced levels of grip/tack. This may help tofacilitate the removal of vacuum bagging materials from forming tool120.

The systems and methods described above provide a benefit over priortechniques because they provide an automated system for preparing acomposite part for curing via vacuum bag techniques. Such systems arenot subject to technician error that may result in leaks or breakswithin a vacuum bag. Furthermore, these systems prevent a technicianfrom being exposed to volatile compounds that may off-gas from anuncured composite part (or its associated vacuum bagging materials).

Enhanced Forming Tools for Vacuum Bag Curing

The following description and figures illustrate enhanced forming toolsthat may be utilized to facilitate vacuum bagging for composite parts.FIG. 12 is a diagram illustrating a forming tool 1200 enhanced withintegrated thermocouples 1210 in an exemplary embodiment. Forming tool1200 comprises any suitable tool configured to adapt a composite part tothe shape of a mold 1240. Forming tool 1200 further comprisesthermocouples 1210, which are coupled to junction box 1220 for reportingand/or recording via wires/traces 1212. Thermocouples 1210 are locatedwithin forming tool 1200, but are coincident with or protrude throughthe surface of forming tool 1200 at locations which will be occupied bya composite part during curing. In this manner, thermocouples 1210 maytouch the composite part, but do not penetrate the composite part. Thus,thermocouples 1210 may directly measure the temperature of the compositepart while it is curing in an autoclave. Additionally, sincethermocouples 1210 are integrated within tool 1200, wires/traces 1212 donot need to penetrate a vacuum bag in order to access thermocouples1210. This reduces the chances of air leaking into the composite part,because it reduces the number of penetrations in the vacuum bag duringcuring.

In one embodiment, junction box 1220 may comprise a multiplexer at theend of at least one of thermocouples 1210. Printing junction box 1220such that its electronics are included within tool 1200 (and thereforewithin an autoclave during curing) may necessitate an amplifier withinjunction box 1220 in order to increase the signal output from integratedthermocouples 1210 within tool 1200. Since many capacitors used inamplifiers will fail in the heat of an autoclave, it may further bedesirable to print any capacitors of the amplifier as solid-statecapacitors.

FIG. 13 is a flowchart illustrating a method 1300 for utilizing aforming tool enhanced with integrated thermocouples in an exemplaryembodiment. To initiate this method, one of dispensers 154 (e.g., an AFPmachine) may apply a ply of constituent material for a composite partonto forming tool 1200. The composite part is vacuum bagged and insertedinto autoclave 1250. In step 1302, autoclave 1250 initiates curing ofthe composite part by heating up to a curing temperature. In step 1304,a controller (e.g., controller 1230, operated by a technician) detects atemperature of the composite part during curing, via thermocouple 1210that is integral with mold 1240 of forming tool 1200. In step 1306, thecontroller 1230 adjusts curing of the composite part, in response to thedetected temperature. For example, if the temperature is too low, thecontroller may increase the curing time, and/or increase the temperaturewithin autoclave 1250. Similarly, if the temperature is too high,controller 1230 may decrease the temperature within autoclave 1250,and/or may decrease the curing time.

FIG. 14 is a block diagram of a system configured to manufactureenhanced forming tools in an exemplary embodiment. System 1400 includescontroller 1410, which directs the operation of 3D printer 1430, as wellas dispensers 1420. 3D printer 1430 comprises any 3D printing systemcapable of printing 3D shapes via metal additive manufacturingprocesses. In this embodiment, printer 1430 comprises interface (I/F)1432, which receives commands from controller 1410 indicating locationsat which to apply heat resistant base material (e.g., metal or a veryhigh temperature plastic) that will be used to form tool 1200. 3Dprinter 1430 draws the material from reserve 1438, heating element 1434heats the material, and nozzle 1436 deposits the material (e.g., asliquid droplets) in order to generate a desired shape for forming tool1200. Dispensers 1420 may comprise 3D printers that operate at roomtemperature, may comprise spray nozzles, etc. Imaging system 1440 may beutilized to guide the operations of 3D printer 1430. For example,imaging system 1440 may detect where electrical components (e.g.,conductors, resistors, etc.) should be printed/dispensed within tool1200, and controller 1410 may direct 3D printer 1430 to print grooves atthese locations within tool 1200 in order to leave room for conductiveelements to be dispensed. These conductive elements/electricalcomponents may be dispensed by dispensers 1420, or by 3D printer 1430printing different materials into the grooves (e.g., insulatingmaterials, thermocouple materials, etc. instead of a stiff basematerial). In one embodiment, 3D printer 1430 includes multiple nozzles,and different nozzles distribute different kinds of materials.

Any suitable technologies for metal printing (e.g., powder bed lasersintering or fused filament fabrication) may be utilized for 3D printingas desired. In a further embodiment, a high temperature plastic may beprinted and/or fused deposition molded, so long as the plastic iscapable of maintaining sufficient stiffness (e.g., enough stiffness toresist deflection at 90 pounds per square inch (PSI) of load) whenheated to approximately two hundred degrees Fahrenheit (F) in autoclave1250.

FIG. 15 is a flowchart illustrating a method 1500 of operating thesystem of FIG. 14 to print a forming tool in an exemplary embodiment.The steps of FIG. 15 are illustrated at FIGS. 16-20, which show printingof an enhanced forming tool 1600 in an exemplary embodiment.

In step 1502, controller 1410 identifies a three dimensional (3D) shapefor forming tool 1600 of FIG. 16. This 3D shape need not be the shape ofa mold/top surface of tool 1600, but comprises the entirety of tool 1600itself. When printed with the 3D shape, forming tool 1600 will beconfigured to hold a composite part while the composite part is curing.A user may program the 3D shape into controller 1410 as a design thatindicates how to print forming tool 1600. Alternatively, a user mayindicate the shape of a mold to use for forming tool 1600, and then relyon controller 1410 to automatically design one or more thermocouplesinto forming tool 1600. When the design has been determined, 3D printer1430 prints (e.g., adds incremental units of) base material in responseto commands from controller 1410. This helps to create a portion of tool1600 based on the 3D shape (step 1504). Part of this process may involveprinting a base layer 1610, as well as an upper layer 1620.

During the printing of forming tool 1600, partway through the build offorming tool 1600, controller 1410 identifies a location 1630 to placean electrical component (e.g., a thermocouple or heating element) withinthe tool 1600 in step 1506. This location may be explicitly indicated ina design stored in memory, or the location may be selected by controller1410 based on an indicated depth for the thermocouple within formingtool 1600, as well as a surfacing location for the thermocouple withinforming tool 1600. After the location has been determined, controller1410 directs printer 1430 to place grooves at location 1630 which thethermocouple will be placed (step 1508).

In step 1510, controller 1410 directs one of dispensers 1420 (e.g., adifferent nozzle of printer 1430, or an entirely separate device) todispense material for the electrical component (e.g., thermocouple) intotool 1600 while tool 1600 is being printed (i.e., before tool 1600 hasfinished printing). This may comprise dispensing a first insulatingjacket 1640 into each groove as shown in FIG. 17, dispensing a firstmaterial 1645 for thermocouple 1650, dispensing additional material forinsulating jacket 1640, and dispensing a second material 1646 forthermocouple 1650, as shown in FIG. 18. The method may further includecovering thermocouple 1650 in insulating jacket 1640, as shown in FIG.19. In one embodiment, thermocouple 1650 is dispensed as a metal clay,and jacket 1640 is dispensed as a ceramic clay, resulting in a 3Dprinted structure within forming tool 1600. In such an embodiment, theclays should be sintered before thermocouple 1650 will be functional.Hence in step 1510, as shown in FIG. 20, controller 1410 directs printer1430 to dispense additional base material 1622 (e.g., liquid metal) ontop of thermocouple 1650 (or any suitable electrical component) to covergrooves and seal thermocouple 1650 into the tool. The metal, heated tomelting or sintering point, bleeds heat into jacket 1640 andthermocouple 1650 (as indicated by the symbol A), which causes both tosinter. Thus, by continuing the 3D printing process to produce thedesired shape for forming tool 1600, controller 1410 also sintersthermocouple 1650 to render thermocouple 1650 functional. Similartechniques may be utilized to print thermocouple plugs and otherfeatures (e.g., integrated antennae for transmitting temperature data)directly into tool 1600. In this manner, these electric/electroniccomponents extend beneath the surface of tool 1600 and are less subjectto wear and tear.

FIG. 21 is a diagram illustrating a further forming tool 2100 enhancedwith integrated heating elements 2110 and electronics in an exemplaryembodiment. In FIG. 21, heating elements 2110 may comprise integrated,sub-surface susceptors or resistors within tool 2100. Heating elements2110 may be utilized to facilitate even heating of a composite partwithin an autoclave, or may even be utilized as an alternative toautoclave curing of a composite part. Heating elements 2110 may beprinted and/or assembled in a similar manner to the thermocouples (e.g.,1210) described above, in order to integrate heating elements 2110 intoa forming tool. In this embodiment, junction box 2120 provides anelectrical connection for heating elements 2110 to receive power.

Junction box 2120 may be implemented as a 3D printed circuit thatexhibits no air cavities between its components, which may enhance theoverall life expectancy of junction box 2120 across many cycles ofautoclave heating.

FIG. 22 is a diagram illustrating application of heat by a forming tool2100 of FIG. 21 in an exemplary embodiment. In FIG. 22, power issupplied from junction box 2120 to resistive heating element 2210 viawire 2130. This causes resistive heating element 2210 to increase intemperature, which heats part 2200 as indicated by the symbol A. Infurther embodiments, forming tools may be printed that includeintegrated heating elements and/or integrated thermocouples, in order toprovide for enhanced temperature measurement and control for a compositepart during the curing process. Heating elements 2210 may be integratedinto forming tool 2100 in a similar manner as described above forthermocouples 1210 of FIG. 12.

In a further embodiment, heating elements 2210 may be selectivelyactivated and deactivated in order to control the temperature variouslocations within a composite part. For example, in an embodiment wheretemperatures are measured at multiple locations on the composite part, acontroller (e.g., controller 1230) may identify a location on thecomposite part corresponding to the detected temperature, and thenselect one or more heating elements 2210 within tool 2100 that areproximate to the identified location. The controller may then adjust theamount of heat generated by the selected heating element(s).

FIG. 23 is a block diagram illustrating an enhanced forming tool 2300 inan exemplary embodiment. In this embodiment forming tool 2300 includes abase layer of metal 2320, to which junction box 2360 is attached.Junction box 2360 includes amplifier 2362 for amplifying incomingsignaling from thermocouples 2350, received via wires/traces 2370.Junction box 2360 also provides power via wires/traces 2380 to one ormore heating elements 2310. Heating elements 2310 are sub-surfaceheating elements placed above metal 2320. Jackets 2340 insulatethermocouples 2350 proximate to metal 2324, and thermocouples 2350include a portion 2352 that protrudes into the surface of mold 2326,ensuring that accurate temperature measurements may be acquired for acomposite part being cured on forming tool 2300.

Recycling of Forming Tools

3D printing techniques may be used to recycle forming tools wheneverdesigns for composite parts are changed. These techniques may also beused to restore forming tools as they degrade over time. Additivemanufacturing processes, such as 3D printing of metal as describedabove, may be utilized in order to reshape an existing forming tool intoa new one.

FIG. 24 is a flowchart illustrating a method 2400 for utilizing additivemanufacturing to modify an existing forming tool in an exemplaryembodiment. In this embodiment, forming tool 2500 of FIG. 25 has beenselected for retooling. This may occur because forming tool 2500 haswarped/degraded over time, or because forming tool 2500 is no longerneeded for manufacturing the composite part it was previously used for.

According to method 2400, in step 2402, controller 1410 operates imagingsystem 1440 to analyze forming tool 2500. Controller 1410 alsodetermines a new 3D shape for forming tool 2500. The new 3D shapeincludes features which are not currently a part of forming tool 2500,but which may be created at forming tool 2500 as part of an additivemanufacturing process. To this end, controller 1410 generatesinstructions in step 2406 for printing heat-resistant material ontoforming tool 2500 in order to alter the shape of forming tool 2500. Step2408 comprises directing 3D printer 1430 to print material onto formingtool 2500, based on the generated instructions. This changes formingtool 2500 into forming tool 2600 of FIG. 26. Forming tool 2600 may beutilized, for example, to facilitate the manufacturing of a differentcomposite part.

Enhancements to Carts Utilized for Autoclave Curing of Vacuum BaggedComposite Parts

The carts discussed herein may also be enhanced with features tofacilitate the curing of a composite part. Specifically, the cartsdiscussed herein may provide an electrical connection to the enhancedtools discussed above.

FIG. 27 is a diagram illustrating an enhanced cart 2750 with anelectrical connector 2756 adapted to mate with a power system 2716 of anautoclave 2700 in an exemplary embodiment. According to this embodiment,cart 2750 is mounted onto rail 2710 of autoclave 2700. Cart 2750 maytherefore move back and forth along rail 2710. In preparation for curingof a part, feet/wheels 2758 of cart 2750 are placed into foot pads 2712of autoclave 2700 and locked in place. Outlet 2714 and connector 2756are dimensioned to mate with each other and form an electricalconnection when cart 2750 is locked into place. In this manner, powermay be supplied from power system 2716, through power system 2754 ofcart 2750, into outlet 2752 of cart 2750, through junction box 2820 oftool 2800, through electrical lines 2830 of tool 2800, and into heatingelements 2810. Similar wiring techniques may be utilized to acquiresignaling from thermocouples mounted in tool 2800. This techniqueprovides a benefit over prior systems, because it does not expose“naked” wiring to the interior of autoclave 2700, decreasing laborcosts, eliminating trip hazards, and reducing thermocouple plug matchrecording errors. FIG. 28 is a diagram illustrating an enhanced cart2750 with an electrical connector 2756 that is mated with an outlet 2714of autoclave 2700. Cart 2750 has been mounted in place for curing, causeconnector 2765 to form an electrical connection with power system 2716.Connector 2765 may additionally or alternatively include signalingwires, thermocouple wires, etc. pertaining to cart 2750, tool 2600,and/or other components for mating with corresponding electricalcomponents of autoclave 2700.

FIG. 29 is a block diagram illustrating an enhanced cart within anautoclave in an exemplary embodiment. As shown in FIG. 29, autoclave2900 includes a heater 2902 which is configured to heat the interior ofautoclave 2900. Autoclave 2900 further includes rail 2910, whichincludes foot pads 2912, outlet 2914, and power system 2916. Cart 2950includes multiple legs 2953. Each leg 2953 includes a foot 2958, and oneof legs 2953 includes connector 2956, which is configured to align withoutlet 2914 when feet 2958 are placed in foot pads 2912. Power system2954 couples connector 2956 to outlet 2952, which is found within body2959 of cart 2950.

EXAMPLES

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 3000 as shown in FIG. 30 and an aircraft 3002 asshown in FIG. 31. During pre-production, exemplary method 3000 mayinclude specification and design 3004 of the aircraft 3002 and materialprocurement 3006. During production, component and subassemblymanufacturing 3008 and system integration 3010 of the aircraft 3002takes place. Thereafter, the aircraft 3002 may go through certificationand delivery 3012 in order to be placed in service 3014. While inservice by a customer, the aircraft 3002 is scheduled for routinemaintenance and service 3016 (which may also include modification,reconfiguration, refurbishment, and so on).

Each of the processes of method 3000 may be performed or carried out bya system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude without limitation any number of aircraft manufacturers andmajor-system subcontractors; a third party may include withoutlimitation any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 31, the aircraft 3002 produced by exemplary method 3000may include an airframe 3018 with a plurality of systems 3020 and aninterior 3022. Examples of high-level systems 3020 include one or moreof a propulsion system 3024, an electrical system 3026, a hydraulicsystem 3026, and an environmental system 3030. Any number of othersystems may be included. Although an aerospace example is shown, theprinciples of the invention may be applied to other industries, such asthe automotive industry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 3000. Forexample, components or subassemblies corresponding to production stage3008 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 3002 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 3008 and 3010, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 3002. Similarly, one or more of apparatus embodiments,method embodiments, or a combination thereof may be utilized while theaircraft 3002 is in service, for example and without limitation, tomaintenance and service 3016. For example, the techniques and systemsdescribed herein may be used for steps 3006, 3008, 2010, 3014, and 3016,and may be used for airframe 3018 and/or interior 3022.

Specifically, the automated placement of consumables for vacuum baggingdescribed herein may be utilized in production stage 3008 in order tofacility component and subassembly manufacturing processes for compositeparts. Enhanced forming tools and carts may also be utilized in asimilar manner. The retooling of forming tools discussed herein may beperformed, for example, as part of maintenance and service 3016 forthose forming tools.

Any of the various elements shown in the figures or described herein maybe implemented as hardware, software, firmware, or some combination ofthese. For example, an element may be implemented as dedicated hardware.Dedicated hardware elements may be referred to as “processors”,“controllers”, or some similar terminology. When provided by aprocessor, the functions may be provided by a single dedicatedprocessor, by a single shared processor, or by a plurality of individualprocessors, some of which may be shared. Moreover, explicit use of theterm “processor” or “controller” should not be construed to referexclusively to hardware capable of executing software, and mayimplicitly include, without limitation, digital signal processor (DSP)hardware, a network processor, application specific integrated circuit(ASIC) or other circuitry, field programmable gate array (FPGA), readonly memory (ROM) for storing software, random access memory (RAM),non-volatile storage, logic, or some other physical hardware componentor module.

Also, an element may be implemented as instructions executable by aprocessor or a computer to perform the functions of the element. Someexamples of instructions are software, program code, and firmware. Theinstructions are operational when executed by the processor to directthe processor to perform the functions of the element. The instructionsmay be stored on storage devices that are readable by the processor.Some examples of the storage devices are digital or solid-statememories, magnetic storage media such as a magnetic disks and magnetictapes, hard drives, or optically readable digital data storage media.

Although specific embodiments are described herein, the scope of thedisclosure is not limited to those specific embodiments. The scope ofthe disclosure is defined by the following claims and any equivalentsthereof.

The invention claimed is:
 1. A method comprising: integrating traces andan integral amplifier into a forming tool during fabrication of theforming tool, including printing a solid-state capacitor into theforming tool; initiating curing of a composite part in a vacuum bagsealed to the forming tool holding the composite part in a definedshape; detecting a temperature of the composite part during curing via athermocouple integrated into the tool, by operating the amplifier toamplify signal output from the thermocouple; and adjusting heat appliedto the composite part in response to the detected temperature.
 2. Themethod of claim 1 wherein: integrating comprises performing additivemanufacturing.
 3. The method of claim 1 wherein: adjusting the heatcomprises altering an amount of electromagnetic energy applied to asusceptor that is integrated within the tool.
 4. The method of claim 1wherein: adjusting the heat comprises altering a temperature of anautoclave surrounding the tool.
 5. A method comprising: integratingtraces and an integral amplifier into a forming tool during fabricationof the forming tool, including printing a solid-state capacitor into theforming tool; initiating curing of a composite part in a vacuum bagsealed to the forming tool holding the composite part in a definedshape; detecting temperatures of the composite part at differentlocations during curing based on input from thermocouples at the formingtool, wherein the forming tool operates the amplifier to amplify signaloutput from the thermocouples; and adjusting amounts of heat applied tothe different locations of the composite part in response to thedetected temperatures by energizing heating elements for the differentlocations.
 6. The method of claim 5 wherein: integrating comprisesperforming additive manufacturing.
 7. The method of claim 5 wherein: theheating elements comprise susceptors, and adjusting the amounts of heatcomprises altering amounts of electromagnetic energy applied to thesusceptors.
 8. The method of claim 5 wherein: each of the heatingelements is at one of the different locations on the composite part, andthe method further comprises: identifying a location on the compositepart corresponding to the detected temperature; selecting one of theheating elements within the tool at the identified location; andadjusting an amount of heat generated by the selected heating element.9. An apparatus comprising: a forming tool configured to hold acomposite part in a defined shape while the composite part is curing ina vacuum bag sealed to the forming tool; a thermocouple integratedwithin the forming tool configured to sense temperature at a surface ofthe tool; traces integrated within the forming tool that carrytemperature signals generated by the thermocouple while the compositepart is curing; an amplifier integrated within the forming tool, whereinthe amplifier includes a solid- state capacitor; and a controllerincluding a processor configured to detect a temperature of thecomposite part during curing via the thermocouple wherein the amplifieramplifies the temperature signals output from the thermocouple, and toadjust heat applied to the composite part in response to the temperatureof the composite part.
 10. The apparatus of claim 9 wherein: thethermocouple is surrounded by an electrically resistive ceramic that isintegrated within the forming tool.
 11. The apparatus of claim 9wherein: the thermocouple comprises a three dimensional (3D) printedstructure within the tool.
 12. The apparatus of claim 9 wherein: thethermocouple includes a portion at the surface of the forming tool wherethe composite part will be placed during curing.
 13. The apparatus ofclaim 9 wherein: the thermocouple extends beneath the surface of thetool.
 14. The apparatus of claim 9 further comprising: at least oneheating element integrated within the forming tool configured togenerate heat that conducts to the surface of the forming tool.
 15. Theapparatus of claim 14 wherein: the at least one heating elementcomprises a resistor that heats the forming tool in response toreceiving electrical current.
 16. The apparatus of claim 14 wherein: theat least one heating element comprises a susceptor that heats theforming tool in response to receiving electromagnetic energy.
 17. Theapparatus of claim 14 wherein: the at least one heating element extendsbeneath the surface of the forming tool.
 18. The apparatus of claim 14wherein: the heating element comprises multiple at least one heatingelements integrated within the forming tool.
 19. The apparatus of claim18 further comprising: at least one of the multiple heating elements isat a location which is occupied by the composite part during curing. 20.The apparatus of claim 18 wherein: each of the multiple heating elementsis at a distinct location which is occupied by the composite part duringcuring.